Lever-Locked Connector Assembly for Vibration-Stable Contact Force
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Solution Overview
Problem
Conventional connector assemblies experience poor contact reliability due to increased contact force requirements, which can lead to difficulty in fitting and potential damage to contact surfaces when used in environments with external forces like vibration.
Innovation Solution
A connector assembly with a contact spring member and a rotational shaft member that elastically deforms to facilitate easy fitting and locking of connectors, using a cam mechanism to ensure reliable contact without excessive force.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a larger contact force is applied between the first contact and the second contact to improve contact reliability, then the contact reliability improves, but the insertion force required for fitting increases and the contact surfaces may be damaged
Solution Approach 1:
The contact spring member is designed to be elastically deformable, allowing it to dynamically adjust its pressing force. During insertion, the spring deforms to reduce resistance, and after insertion, it exerts sufficient contact force to ensure reliable electrical connection, thus resolving the contradiction between ease of fitting and contact reliability
Solution Approach 2:
The pressing force of the contact spring member is designed to change based on the insertion state. When the lever member is in the second rotational position, the spring is compressed to reduce insertion force; when the lever is rotated to the first positional position, the spring expands to provide adequate contact force, dynamically adapting the force parameter to different operational phases
2Reliability
If a larger contact force is applied between the first contact and the second contact to improve contact reliability, then the contact reliability improves, but the contact surfaces may be damaged leading to lower contact reliability
Solution Approach 1:
The elastic contact spring member provides a dynamically adjustable contact force that is sufficient for reliable electrical connection but controlled to prevent surface damage. The spring's elasticity allows it to absorb excessive forces and maintain consistent, non-damaging pressure on the contact surfaces
Solution Approach 2:
The contact spring member acts as a cushioning element between the contacts, absorbing and distributing forces to prevent direct impact and potential damage to the contact surfaces while ensuring adequate contact pressure for reliable electrical connection
3Power
If thick electric wires are used to handle increased electric current, then the current carrying capacity improves, but the transmission of external forces like vibration to the contact points increases resulting in poor contact
Solution Approach 1:
The contact spring member serves as an intermediary element between the thick electric wires and the contact surfaces. It isolates the contact interface from vibrations transmitted through the wires by providing elastic compliance, thus maintaining reliable contact despite the presence of thick current-carrying wires
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution enhances contact reliability and ease of fitting while minimizing the risk of damage to contact surfaces, even under external forces like vibration.
Implementation Method 1
the cam surface of the rotational shaft member elastically deforms the contact spring member
Data Source
AI summary
The connector assembly includes a first connector having a first insulator and a first contact, a second connector having a second insulator and a second contact and being fitted to the first connector along a fitting direction, a contact spring member attached to the second contact and pressing the first contact against the second contact, a lever member held by the second insulator and being rotatable about a rotational axis between a first rotational position and a second rotational position, a rotational shaft member held by the second insulator to rotate about the rotational axis with rotation of the lever member and having a cam surface configured to elastically deform the contact spring member, and a fitting cam mechanism moving the first insulator and the second insulator relatively along the fitting direction in conjunction with rotation of the lever member.